Additive tool cuts costs for Xcel Aerospace

Working closely with companies like Rolls-Royce, Collins Aerospace, Safran, Bombardier, ITP Aero, Marshall and Incora, Romford-based Xcel Aerospace is a subcontract manufacturer with an aerospace pedigree that few in the supply chain can match.

As part of its drive to ensure cost-effective manufacturing, the company recently invited tooling manufacturer Guhring to review the machining process on an aerospace valve component. The problem for Xcel was the cost efficiency of its existing Woodruff-type cutters when machining the cast aluminium component, which features 9% silicon content.
Only capable of completing 10 components before tool replacement, the abrasive aluminium was creating productivity, cost and surface finish issues for this aerospace expert.
“We explained to Xcel that Guhring has a new method of manufacturing PCD tools by printing them on a MarkForged Metal X 3D-printing machine,” says Guhring’s regional sales manager Dewar McKinlay. “We made a three-flute tool that was similar to the current tool but with brazed PCD tips. Despite the PCD tips lasting considerably longer on the abrasive high-silicon aluminium than the previous tool, we wanted to go further.”
The new design increased the number of cutting edges from three to five, allowing Xcel to increase the feed rate, while extending tool life.
“The previous solid-carbide tool was worn and required a changeover after 10 parts, but we have machined more than 180 parts with the new 3D-printed PCD Woodruff cutter and it is still performing well,” says McKinlay.
“Putting five cutting edges on a 21.7 mm diameter Woodruff tool with a solid-carbide body would create significant manufacturing challenges,” he adds. “The main benefit of printed tools is that we can produce multiple designs very quickly.”
For further information www.guhring.co.uk

Low-cost, high-performance turning inserts

As the manufacturing sector begins its recovery from the downturn attributed to COVID-19, Ceratizit has stepped up to provide a helpful hand in controlling tooling costs.

The introduction of its Standard Line of ISO turning inserts is said to provide customers with significant cost benefits, while retaining quality and performance.
In order to achieve these cost savings for customers, Ceratizit has streamlined the Standard Line into just three grades, with a reduced number of seven insert shapes. These shapes include the popular CNMG, DNMG, CCMT and DCMT styles, in a range of insert sizes, giving over 100 inserts from which to select. As highlighted by the insert designations, both positive and negative inserts are available, with a choice of two chip-breaker styles to suit specific machining applications.
Standard Line inserts are manufactured to the company’s exacting standards at Ceratizit’s Reutte, Austria facility, and by limiting the range to the most popular styles and sizes, volume manufacturing is helping to drive down costs.
“The Standard Line of turning inserts will benefit many customers, particularly those in the subcontract sector, where batch sizes may be low and frequently changed, and where business is price-focused,” explains Tony Pennington, managing director of Ceratizit UK & Ireland. “For example, savings when compared with mainstream competitors can be as high as 75% per insert, giving customers the competitive edge they are looking for in these challenging times.”
Standard Line turning inserts are available ex-stock with the same delivery promise as with all of Ceratizit’s products; if ordered by 18:30, delivery is guaranteed the next morning before noon.
For further information www.ceratizit.com

£6.85m funding for NAMRC facility

The Nuclear AMRC’s proposal to establish a new advanced manufacturing research centre in Derby has secured government funding.

Supported by Derby City Council and the D2N2 Local Enterprise Partnership, the proposal has been awarded £6.85m by the Ministry of Housing, Communities & Local Government. Local partners will also invest in the proposed £20m project to create a new permanent home on Derby’s Infinity Park for Nuclear AMRC Midlands, creating 70 jobs and helping to reboot the local economy after the coronavirus crisis.
For further information www.namrc.co.uk

Five-axis investment pays dividends

Significantly reduced machining operations leading to reduced part cycle times, improved operational efficiencies and new business wins are just some of the benefits that Baker Engineering is experiencing from its latest Doosan five-axis machining centre investment.

Mills CNC, the exclusive distributor of Doosan machine tools in the UK and Ireland, supplied Baker Engineering, a precision toolmaker and engineering subcontract specialist based in Derby, with the new Doosan DVF 5000. The machine was installed at the company’s new, purpose-built 8000 sq ft facility in April 2020, where it is being used to produce a diverse range of precision components, as well as specialist tooling, jigs and fixtures for its growing UK and international customer base.
Baker Engineering’s DVF 5000 is the second Doosan machine tool to arrive on site, the first being a new DNM 6700 vertical machining centre, which was acquired in February 2017.
Baker Engineering is a family-owned business established in 2008 that today employs 15 members of staff. The company is ISO9001-accredited and committed to continuous improvement, making regular investments in the latest machine tool and ancillary manufacturing technologies to maintain its competitiveness and strengthen its preferred partner relationships with customers.
A number of CNC machines can be found on site at Derby, including machining centres with integrated 4th-axis units, lathes with bar feeders, and wire EDM machines. In addition to offering precision subcontract machining services, the company has specific strengths in manufacturing aerospace component tooling (such as jigs and fixtures for ground support maintenance); tooling for the measurement and inspection of railway tracks; and tooling used in the power-generation sector.
As a forward-thinking company the decision to invest in the latest five-axis machining technology was a natural one, and had begun in earnest earlier in 2019.

Explains director Adrian Baker: “Multi-axis and multi-tasking machine tools help manufacturers improve their productivity. We’re a company that’s looking to constantly improve; we had done our homework into the technology and could see that an investment in a five-axis machine tool would deliver significant performance benefits. In addition, the investment would send the right signal, externally and internally, that Baker Engineering was focused on the future.”
The key advantages from investing in five-axis machine tool technology were immediately apparent to management and staff at the company and included: the ability to machine complex shapes/parts in a single set-up; the added benefit that ‘one-hit’ machining has on reducing the time and costs involved in set ups; and the ability to improve/maintain part accuracies owing to a reduction in work handling.
“Since the installation of the DVF 5000 we have experienced all of these benefits,” states Baker.
A demonstration of the machine’s capabilities, and its impact on Baker Engineering’s performance, can be seen when machining an electrical housing-type component. Prior to the arrival of the DVF 5000, this part was completed in five separate machining operations with a cycle time of 2.5 hours. However, when machined on the DVF 5000, the number of operations can be reduced to two, with a cycle time of 45 minutes.
“This is typical of the results we have been able to achieve since our investment in the machine,” says Baker.
Prior to making the purchase decision, Baker Engineering investigated the market in order to help identify the type of machine that would “fit the bill”.
“We were pleased with the DNM 6700 vertical machining centre that we bought in 2017 in terms of its performance and reliability, and have been impressed with Mills’ aftersales service and support,” says Baker. “When considering the five-axis machine investment it was natural that we approached them to discuss our requirements.”

The company’s discussions with Mills CNC led to the recommendation of the DVF 5000, which is a best-selling five-axis machine from Mills CNC’s machine-tool portfolio. This compact and rigidly-built machine is said to deliver high cutting performance and machining flexibility. The machine offers full simultaneous five-axis machining capability as well as 3+2 and 4+1 operations. Baker Engineering is predominantly using the machine for 3+2 and five-face machining.
Baker Engineering’s new DVF 5000 features a direct-drive spindle (up to 18.5kW/12,000rpm), linear guides and a 500 x 450 mm work table with 400 kg table load. The machine boasts 40 m/min rapids and was supplied to Baker Engineering with a 60-position ATC, integrated tool measurement and the latest Fanuc 0iMF control.
Since installation at the end of April, the DVF 5000 has been in constant use at Baker Engineering’s facility. As well as it helping the company increase its productivity and efficiency, the machine has also helped win new machining work.
“News travels fast,” states Baker. “On hearing that we had invested in Doosan five-axis machine-tool technology, a new customer made contact asking us to quote on a job. We have successfully turned that enquiry into an order.
“Our decision to invest in the Doosan DVF 5000 has been vindicated,” he concludes. “The machine has significantly strengthened our machining capacity and capabilities. It is fast, accurate and reliable, and represents great value.”
For further information www.millscnc.co.uk

Hurco automated production demonstrator

Following the UK launch by Hurco at the end of 2019 of a portable cobot (collaborative robot) range, the company has set up a new manufacturing cell at its High Wycombe technical centre to help potential customers across Britain and Ireland see the way in which machine-tool tending may be simply and inexpensively automated.

Hurco is keen to showcase the productivity and cost benefits that come from maximising spindle uptime. The cobot installed in the demonstration cell has a twin gripper attachment and feeds a Hurco TM8i three-axis CNC lathe.
For further information www.hurco.co.uk